Review full instructions prior to use for important safety information. Always check Rockler.com to confirm that you are using the most recent version of instructions for your product.

Table Saw Crosscut Sled InstructionsEffective November 2019

2 BP0918

GENERAL SAFETY WARNINGS

This product is designed only for specific applications as defined in the instructions and should not be modified or used for any manner not described in these instructions. Use only recommended accessories. Before using the Table Saw Crosscut Sled: READ, UNDERSTAND and FOLLOW ALL INSTRUCTIONS AND SAFETY WARNINGS. KEEP THESE INSTRUCTIONS READILY AVAILABLE FOR FUTURE REFERENCE.

> Always confirm that you are using the most recent version of the Instructions and safety warnings for your product (see the Instructions link on the product page at Rockler.com).

> Before using another tool with this product, always read, understand and follow the instructions and safety warnings in the owner’s manual for that tool. If you do not have the owner’s manual, obtain one from the tool’s manufacturer before using it with this product.

> Before using any chemical with this product, always read, understand and follow all safety warnings and guidelines in the manufacturer’s Safety Data Sheet (SDS; formerly called “MSDS”), especially regarding: • How to safely use the chemical, including potential hazards and recommended first aid measures; • Personal safety equipment required to safely use the chemical (e.g. gloves, eye protection, mask/respirator, etc.); • Proper and safe handling, storage and disposal of the chemical.

> Before using this product, review and verify that all tools to be used with it have safety equipment installed and are in proper working order as defined by the tool’s owner’s manual.

> Do not use this product until you have read and are confident you understand: • Product Specific Safety Warnings (p. 3); • Setup (pp. 4 - 5); • Use (pp. 6 - 7).

> The user assumes all risk and responsibility for the proper and safe use of this product and for ensuring product suitability for the intended application.

> It is the sole responsibility of the purchaser of this product to ensure that any anyone you allow to use this product reads and complies with all instructions and safety precautions outlined in this manual prior to use.

> Follow all standard shop safety practices, including:

• Keep children and bystanders away from the tool operating area; • Do NOT use power tools in explosive environments, or in the presence of flammable liquids, fumes or dust; • TURN OFF AND UNPLUG all power tools BEFORE making any adjustments or changing accessories; • Remain alert and use good judgment. Do not use this product if you are in any way impaired by medications, alcohol, drugs or fatigue; • Keep your work area well lit and clean; • Dress appropriately. Secure loose clothing, remove all jewelry and tie up long hair before using this product; • ALWAYS wear safety glasses, hearing protection and respiratory protection that complies with NIOSH/OSHA/ANSI safety standards; • Use dust collection tools and dust face masks to reduce exposure to dust; • Use safety equipment such as featherboards, push sticks and push blocks, etc., when appropriate; • Maintain proper footing at all times and do not overreach; • Do NOT force woodworking tools.

> These warnings and instructions do NOT represent the total of all information available regarding tool safety, use and technique. Always seek out opportunities to learn more and improve your skills and knowledge.

Drilling, sawing, sanding or machining wood products can expose you to wood dust, a substance known ot the State of California to cause cancer. Avoid inhaling wood dust or use a dust mask or other safeguards for personal protection. For more information go to www.P65Warnings.ca.gov/wood.

Danger indicates a hazardous situation that, if not avoided, will result in death or serious injury.

Warning indicates a hazardous situation that, if not avoided, could result in death or serious injury.Caution indicates a hazardous situation that, if not avoided, may result in minor or moderate injuryor property damage.Notice indicates important or helpful information and/or user tips.

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PRODUCT SPECIFIC SAFETY WARNINGS

> To avoid serious injury, keep hands out of the path of the spinning blade. Maintain awareness of the blade at all times.

> Always turn off and unplug the saw when making any adjustments.

> The Table Saw Crosscut Sled is intended for use only on cabinet and full-size contractor-grade table saws with a standard 3/8"D x 3/4"W miter slot. It is NOT intended for use on portable saws.

> The distance between the blade and miter track must be 41⁄4" or greater to ensure proper clearance between the sled fence and the blade.

> Make sure that you have sufficient outfeed support and that the outfeed support does not obstruct the path of the Crosscut Sled’s miter bar.

> Do NOT use your table saw’s rip fence when using the Crosscut Sled.

> Do NOT use the Crosscut Sled with dado blades.

> The Crosscut Sled is not intended for making compound cuts.

> In the setup process, the Crosscut Sled is cut to fit your specific saw. Read the instructions carefully to complete this essential setup step.

> The hold-down clamp and sled fence MUST be positioned so that they will NOT come into contact with saw blade.

> You MUST tighten all knobs and the hold down to secure the workpiece after making any adjustments and before making any cuts.

> Keep the saw blade as low as possible to make the cut, as defined by your table saw’s instruction manual.

> The Miter Bar MUST be able to slide freely forward and backward without side-to-side play. NEVER attempt to force the jig if it fails to slide freely.

> Before making the actual cut, become familiar with the cutting process by practicing the motion of the cut with the blade lowered and the power turned off.

> Do NOT attempt to cut pieces that are too short to be secured to the sled with the hold-down clamp.

> STOP USING THE JIG IMMEDIATELY if any component develops a crack or other sign of the loss of structural integrity.

For zero-clearance support on both sides of the blade, and smoother cuts, we recommend using the Drop-Off Platform (37541, sold separately) with the Crosscut Sled.

4

Setup

THESE WARNINGS PERTAIN TO ALL REMAINING STEPS:

> To avoid serious injury, keep hands out of the path of the spinning blade. Maintain awareness of the blade at all times.

> Always turn off and unplug the saw when making any adjustments.

> The Table Saw Crosscut Sled is intended for use only on cabinet and full-size contractor-grade table saws with a standard 3/8"D x 3/4"W miter slot. It is NOT intended for use on portable saws.

> The distance between the blade and miter track must be 41⁄4" or greater to ensure proper clearance between the sled fence and the blade.

1. Unscrew the five-star knobs that hold the fence to the Crosscut Sled platform and separate the two parts.Fig. 2

Fig. 1 - Bottom View

Place self adhesive low-friction tape strips as shown

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2. Apply the self-adhesive low-friction tape strips to the underside of the platform and underside of the aluminum fence. Fig. 1.

3. Reinstall the fence on the platform with the five-star knobs.

4. Check to make sure your table saw’s blade is parallel to the table’s miter slots and 90˚ to the table. If it isn’t, follow the saw manufacturer’s guidelines to make necessary adjustments so that it is parallel to the miter slots and square to the table.

5. Lower the blade below the table surface.

6. Fit the miter bar on the Crosscut Sled into the left miter slot on your table saw and slide it to assess the fit. The Crosscut Sled should slide easily but not shift side to side.

7. If adjustments are needed, turn the Crosscut Sled over and use the smaller of the two included hex wrenches to tighten or loosen the spring-loaded ball bearings on the miter bar. Flip the sled back over and test it on the saw table again. Adjust the spring-loaded bearings again, if necessary, until a smooth, slop-free fit is achieved.

8. Before using the Crosscut Sled, you will need to trim the platform. Place the Crosscut Sled on the saw table, clear of the blade, with the miter bar in the miter slot. Make sure that the MDF subfence is retracted enough so that it won’t be cut, and then turn on the saw, raise the blade and push the sled through to make the cut. The edge of the Crosscut Sled now precisely locates the cut line and provides zero-clearance support to minimize tear-out. Fig. 2.

9. The next step is to set the fence square to the saw blade. If necessary, loosen the five-star knobs to allow you to adjust the fence.

10. Set a reliable combination square against the blade and adjust the fence until it is precisely 90° to the saw blade. (Make sure the square contacts only the plate of the blade and not the teeth.) Tighten the five-star knobs to lock down the fence. Fig. 3. The line on the acrylic indicator might not line up with 0° angle mark on the protractor scale at this point; you will adjust the indicator in Step 12.

11. With the fence square to the blade, use the larger of the two included hex wrenches to turn the threaded screw in the fence stop so that it contacts the back of the fence. This screw will act as a stop every time you return the fence to 0°. Fig. 4.

12. Use a screwdriver to adjust the acrylic indicator so that the red line is directly over the 0° angle mark. Fig. 5.

13. Install the hold-down clamp by inserting the T-bolt from the underside of the platform, positioning the hold down and threading on the five-star knob.

The Miter Bar MUST be able to slide freely forward and backward without side-to-side play. NEVER attempt to force the jig if it fails to slide freely.

Fig. 5

Fig. 4

Fig. 3

6

Use

Fig. 6 Fig. 7

THESE WARNINGS PERTAIN TO ALL REMAINING STEPS:

> Make sure that you have sufficient outfeed support and that the outfeed support does not obstruct the path of the Crosscut Sled’s miter bar.

> Do NOT use your table saw’s rip fence when using the Crosscut Sled.

> Do NOT use the Crosscut Sled with dado blades

> The Crosscut Sled is not intended for making compound cuts.

> The hold-down clamp and sled fence MUST be positioned so that they will not come into contact with saw blade.

> You MUST tighten all knobs and the hold down to secure the workpiece after making any adjustments and before making any cuts.

> Keep the saw blade as low as possible to make the cut, as defined by your table saw’s instruction manual.

> The Miter Bar MUST be able to slide freely forward and backward without side-to-side play. NEVER attempt to force the jig if it fails to slide freely.

> Before making the actual cut, become familiar with the cutting process by practicing the motion of the cut with the blade lowered and the power turned off.

> Do NOT attempt to cut pieces that are too short to be secured to the sled with the hold-down clamp.

> STOP USING THE JIG IMMEDIATELY if any component develops a crack or other sign of the loss of structural integrity.

> To avoid serious injury, keep hands out of the path of the spinning blade. Maintain awareness of the blade at all times.

> Always turn off and unplug the saw when making any adjustments.

Tighten five-star knob to lock the fence in place

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1. Position the Crosscut Sled at the front of the saw, clear of the blade.

2. Set the fence to the desired cut angle by referring to the protractor scale and acrylic indicator and lock it in place by tightening the five-star knobs. Fig. 6.

3. If desired, the MDF subfence can provide zero-clearance support to minimize tear-out on the back of the cut. Extend or retract the subfence by loosening the three small knobs on the fence, sliding the subfence and retightening the knobs. If you don’t want the subfence to be cut, retract it out of the blade’s path.

4. Make sure the blade height is sufficient to cut through your workpiece when it is on the Crosscut Sled.

5. Place your workpiece on the sled, tight to the jig fence, and line up the desired cut line with the edge of the sled.

6. Clamp your workpiece to the sled by positioning the hold-down clamp and tightening the five-star knob. Fig. 7.

7. Turn on the saw and slowly advance the sled to make the cut. Once through, turn off the saw and allow the blade to stop spinning before returning the sled to the front of the saw. Fig. 8.

8. If you need to cut multiple pieces to the same length, slide the included flip stop onto the T-track slot at the top of the fence and set it at the desired distance. Then you can simply butt the end of subsequent workpieces against the movable arm to cut multiple matching pieces. Fig. 9.

Fig. 8

Fig. 9

You MUST tighten all knobs and the hold down to secure the workpiece after making any adjustments and before making any cuts.

Do NOT attempt to cut pieces that are too short to be secured to the sled with the hold-down clamp.

Check Rockler.com for updates. If you have further questions, pleasecontact our Technical Support Department at 1-800-260-9663 or support@rockler.com

Distributed by Rockler Companies, Inc. 4365 Willow Dr. Medina, MN 55340

33113Rev 11/19

1-800-279-4441www.rockler.com